Cutting and Fabricating - Universal Metaltek · 2018-04-19 · steel with sealing washer that have...
Transcript of Cutting and Fabricating - Universal Metaltek · 2018-04-19 · steel with sealing washer that have...
Cutting and Fabricating
Sawing
Blade geometry Tooth thickness approximately 2mm – 4mm
Tapered to the side to prevent jamming
Tooth geometry Trapeze tooth / flat tooth
Pitch (t) 10mm to 12mm
Clearance angle (α) 15°
Rake angle (γ) 10° positive
Maximum cutting speed (v) 5,000 m / min.
Maximum feed (s) 30m / min
Routing
HONYLITETM
honeycomb panel can be easily routed on conventional routing machines.
To avoid pressure marks on the surface, please use plastic or wood vice jaws when chucking the
work-pieces. High speed steel or carbide tipped cutters suitable for aluminium have a wide tooth
pitch, reduced and smooth grooves and small lip angles.
The produce perfect cuts under the following conditions:
High speed steel (HSS)
Maximum cutting speed 3,000m / min.
Maximum feed 25m / min.
Carbide tipped (CT) cutters
Maximum cutting speed 5,000m / min.
Maximum feed 30m / min.
Drilling
HONYLITETM
honeycomb panel can be drilled with twist drills normally used for aluminium and
plastics on machines common for metals.
Drill material:
High-speed steel (HSS)
Tool geometry:
Lip angle: 100ᵒ to 140ᵒ
Pressing / Stamping
HONYLITETM
honeycomb panel can be pressed. The core is compressed without destroying the
viscoplastic bonding system. This offers new processing and application possibilities.
Bending with a Roll Bending Machine
HONYLITETM
honeycomb panels of 6mm and 10mm
thickness can be bent using three and four-roll bending
machines with relatively close radii. The viscoplastic
composite system enables radii to the produced from
300mm with a panel thickness of 6mm and from 700mm
with a panel thickness of 10mm. The minimum diameter
of the rolls should be 150mm.
The values for adjusting the rolls have to be determined
by trial. The bending rolls must be thoroughly cleaned of
swerve before processing.
The surface should be protected from damage by affixing plastic strips of 1mm to 2mm thickness
during processing.
Step-bending with bending presses
HONYLITETM
honeycomb panels can be shaped using the
step-bending process. The bending radius is determined by
the stamping depth, the stamping distance and the panel
thickness
Bending with saw cuts
HONYLITETM
honeycomb panels can be bent by
applying saw cuts on the rear side of the panel.
The required radius (r) is determined by the tooth
thickness (s), the wall thickness (b), the panel
thickness (d) and the number of saw cuts.
To obtain a final thickness of 1.3mm,
corresponding tracing rollers are attached to the
saw blades of the vertical panel saws. Principally,
bending should take place in the 1mm thick cover
sheet.
Folding Technique
Folding with the bending press
HONYLITETM
honeycomb panels can be folded on bending presses using the
tool geometry.
When measuring cuts, the material gain for the corresponding thickness
must be taken into consideration when making 90ᵒ folds.
Panel
Thickness
(mm)
Bending
Radius
Outside
(mm)
Material
Gain
(mm)
Folding
Height
min.
(mm)
6 -4 2.7 20
10 -9 5.0 25
15 -13 7.5 30
20 -16 8.5 50
25 -18 10.0 50
Routing & Folding technique / producing corners and edges
Corers and edges can be produced simply on
HONYLITETM
honeycomb panels using the
routing and folding technique. With all
versions, a groove is routed on the rear of the
panel into the 1mm thick cover sheet at the
front.
In version 1, as with HONYLITETM
honeycomb
panel, a cutter disk or forming cutter for V-
groove 90ᵒ is used in the appropriate width.
In version 2, the core of the panel is pre-cut
using special tools.
The grooves can be produced with circular
panel saws. Normally, folding by hand is
possible. If his is not possible, we recommend
the use of a folding machine.
Panel Edgings
Producing edgings using panel edging sections
Depending on the type of application, edging sections of various shapes can be attached to the ends
of the HONYLITETM
honeycomb panel. They are fixed to the panel by bonding, clamping or riveting to
the cover sheet.
Jointing and Fixing Techniques
HONYLITETM
honeycomb panel can be joined by means of standard processes used in metal and
plastics technology. If HONYLITETM
honeycomb panel is to be joined to structural parts of metals
other than aluminium, or if fasteners (e.g. bolts, screws) are to be used, the following materials
guidelines should be observed:
� Fasteners and structural parts made of aluminium, plastic or stainless steel should be
suitable for assembly with HONYLITETM
honeycomb panels.
� When using other materials, please insert insulating washers or apply protective a coating to
prevent corrosion.
� Please take the thermal expansion of the panel into account for outdoor use of HONYLITETM
honeycomb panel to avoid jamming or deformation.
� The minimum gap depends on the expected expansion of the panel.
� The linear thermal expansion of HONYLITETM
honeycomb panel is determined by the
aluminium cover sheets.
� At a temperature difference of 100ᵒC, the longitudinal deformation is 2.4mm/m
length/width.
Rivets – Not Penetrating the Panel
Rivets generally must be anchored in the 1mm thick
cover sheet of HONYLITETM
honeycomb panel.
Sections can be attached to HONYLITETM
honeycomb
panel with commercially available rivets for aluminium
constructions. After drilling a blind hole of the same
diameter as the rivet shank, the rivets can be anchored
in the cover sheet. As a rule, rivets with stainless steel
mandrel are used.
Rivets – Penetrating the Panel
HONYLITETM
honeycomb panel can be joined together or fastened to other materials using rivet
types commercial available for aluminium constructions. For outdoor use and for use in areas of high
humidity, aluminium blind rivets with stainless steel mandrels are normally used to prevent ugly
corrosive edges. When using aluminium blind rivets with steel mandrels, the mandrel should drop
out after riveting.
Countersunk rivets are not suitable.
For outdoor use, please note:
Use aluminium blind rivets that have been approved for construction with a 5mm shank diameter
and an attachment head diameter of 11mm or 14mm.
Please take the thermal expansion of the panel into account (2.4mm/m/100ᵒC). To avoid jamming,
the hole in the panel must be large enough to allow for expansion.
With the shank of the rivet fitting closely to edge of the hole, the attachment head must cover over
1mm of the area surrounding the hole.
Multi-step drills or sleeves having corresponding diameters are used for centrically drilling holes into
the panel and the substructure and for centrically fitting the rivet.
Rivet attachment jigs are used for fitting blind rivets without jamming allowing for a tolerance of
0.3mm. Make sure the use rivet attachment jigs and rivets from the same manufacturer, as the
height of the attachment head according to DIN 7337 may vary.
The clamping thickness results from the thickness of the material to be riveted plus an additional
value of 2mm to ensure that the closing head is perfectly formed. In accordance with this clamping
thickness, the corresponding shaft length is determined in the tables provided by the rivet
manufacturers.
Important:
During riveting, many factors may have an influence on the exact tolerance of the rivets of 0.3mm
(e.g. rivet head tolerance). We therefore recommend that you make a test on a façade panel.
Please always remove the protective film around the riveting area prior to riveting.
Blind Rivet Nuts and Bolts
Blind rivet nuts and bolts are threaded elements performing the function of a blind rivet and a nut or
bolt (screw).
There are various types of rivet head and materials which can be selected depending on the
intended application. The blind rivet nuts or bolts are inserted in blind holes drilled in one side of the
HONYLITETM
honeycomb panel. Subsequent fitting with a tool is fast and cost-effective.
Due to the minimum shaft length of 11mm, these fixtures can only be used for a panel thickness of
15mm or more. As a rule, the rivet must be anchored in the 1mm thick cover sheet.
Threaded Fasteners for Outdoor Use Please take the thermal expansion of the panel into account when using
threaded fasteners outdoors. To avoid jamming, the hole diameter in the
panel must allow for the expansion.
Fastening without jamming is possible with fascia screws made of stainless
steel with sealing washer that have been approved for construction. The
screws must be suitable for the corresponding substructure. The screws
should be tightened with a torque wrench or screw driver so that the
sealing washer is placed on the panel for sealing the bore hole without
exerting pressure onto the panel.
Multi-step drills or sleeves having corresponding diameters are used for
centrically drilling holes into the panel and the substructure and for
centrically fitting the rivet.
Important:
Please always remove the protective film prior to screwing
Flowdrill Process
Flowdrills are polygonally ground carbide-tipped tools.
The Flowdrill presses against the thin metallic material with a relatively
high rotational speed and axial pressure. The generated heat makes the
material soft enough to push the Flowdrill through the work piece thus
forming a hole. The material which is mainly displaced in process direction
forms a bushing at the same time. The length of the bush can be 3 to 5
times the original material thickness.
In the case of threaded fasteners
higher pull-out strength can be
obtained due to the larger contact
area of the screws.
The “flat / short” Flowdrill type is used
for HONYLITETM
honeycomb panel.
These drills are suitable for thin
materials and remove protruding
material from the panel surface at the
same time.
Clamp Connections
Clamp connections incorporating
aluminium or plastics are
particularly suitable for
HONYLITETM
honeycomb panel.
They generally consist of two parts
with the clamping effect achieved
by bolting.
Various designs of clamping
element are used for display and
store fitting purposes.
Any suitable connection or shock-
resistant frame can be easily be
made with aluminium sections.
For fascia cladding applications
special aluminium sections are
provided for clamp connections.
Gluing
Tapes / Velcro Tapes
Double-sided tapes (such as the 3M-VHB high capacity jointing systems) can be used for the above
applications with low tensile or transversal strength requirements.
Metal Adhesives / Universal Adhesives
For indoor use, trade fair / exhibition stand structures and machines, most metal or universal
adhesives are suitable.
General Notes
Processing / Installation
To avoid possible reflection differences (for metallic colour), we recommend installing the panels in
the direction of the marking shown on the protective film of individual panels.
Removal of Protective Film
It is recommended removing the protective film as soon as possible after the installation. Due to UV
radiation, it may occur that residual glue sticks to the surface of the panels.
Cleaning and Maintenance
The frequency with which cleaning is to be carried out and the choice of a suitable cleansing agent
depends largely on the position of the building being cleaned and the degree of contamination.
The cleaning operation should be carried out in stages staring from the top and working downwards.
It can be carried out manually or with the aid of special cleaning apparatus such as high pressure
sprays, with the addition of suitable cleansing agents.
The cleaning operation must be followed by a thorough rinse with clean water to ensure the
removal of all remnants of the cleansing agent. A final wipe down by means of a sponge, leather or
wiper is necessary to avoid water stains.
Do not clean sun-heated surfaces (>40ºC) to avoid rapid drying which may lead to stain formation.
Avoid both strongly alkaline agents (such as caustic soda) as well as strongly acid products. Similarly
unsuitable are abrasives such as Vim, Ajax, etc, or solvents that are likely to attack the lacquer.
Products offered in the trade for metal cleaning should on no account come in to contact with the
stove lacquered aluminium surfaces.
Storage
Protect HONYLITETM
panels during storage against rain, moisture penetrating the pallets and
condensation. Store the pallets stacked one on top of the other; stacks must not comprise more
than 6 pallets of identical size. Storage exceeding 6 months should be avoided.
To avoid marks, do not place anything between the panels when stacking them.
Transport
Pallets must be handled carefully during transport and unloading. (Caution: do NOT move open
pallets)
Upon delivery, pallets must be examined for any damages. Any damage must be reported
immediately and confirmed by the forwarding agent.
Handling
Individual panels must be lifted off the pallet by two people holding all four corners and not drawn
over each other. Carry panels vertically. Wear gloves to avoid making any marks on them.
Delivery Lead Time
Upon confirmation of colour and receipt of payment it takes minimum 4 to maximum 6 working
weeks to reach designated discharging port.
Product Warranty
HONYLITETM
honeycomb panels were being warranted to be free from defects in manufacturing and
workmanship for the duration for 15 years (for PVDF coating) / 10 years (for
PE coating)